The rise of phosphate-bonded refractory bricks aligns with the global trend of high-temperature industrial upgrading and the green transformation of the refractory materials industry. Their production process does not require high-temperature sintering, significantly reducing coal consumption and exhaust emissions. Compared to traditional sintered refractory bricks, their energy consumption is reduced by more than 50%, highlighting their environmental advantages. Moreover, their high-temperature service performance far exceeds that of ordinary non-sintered refractory materials, capable of withstanding temperatures above 1200°C, and their service life is 40% longer than that of ordinary refractory bricks, making them the preferred refractory material for high-end high-temperature equipment. However, the quality control of phosphate-bonded refractory bricks is extremely challenging - as they rely on the chemical reaction of phosphate binders for bonding and forming, the density uniformity, porosity, and binder dispersion of the green body directly determine the high-temperature strength and erosion resistance of the finished product. Any deviation in the forming process can easily lead to insufficient compressive strength of the finished product, easy powdering and flaking at high temperatures, and a decline in thermal shock resistance, making them unsuitable for high-end high-temperature applications. Therefore, the forming of phosphate-bonded refractory bricks must meet six core requirements: uniform density, dense structure, uniform binder dispersion, no cracks, intact edges and corners, and precise dimensions. It is necessary to ensure uniform density throughout the green body, ensuring that the compressive strength at room temperature of the finished product is ≥ 40 MPa, the high-temperature compressive strength is ≥ 25 MPa, and the apparent porosity is controlled within a reasonable range of 15% - 20%, meeting the service requirements of high-temperature conditions. At the same time, it is necessary to precisely control the pressure application speed and holding time to adapt to the poor fluidity and difficult exhaust of the phosphate-bonded refractory brick mixture, avoiding residual pores in the green body that can lead to insufficient strength of the finished product. It is also necessary to precisely match the forming pressure requirements of different specifications and uses of phosphate-bonded refractory bricks, avoiding cracking due to overpressure and porosity due to underpressure, while ensuring uniform dispersion of the phosphate binder to fully leverage its bonding and strengthening effects and avoid local performance defects caused by binder aggregation. Currently, the technical shortcomings of traditional forming equipment have led to widespread problems in the production of phosphate-bonded refractory bricks, such as uneven green body density, substandard strength, edge and corner damage, large dimensional deviations, uneven binder dispersion, low product qualification rates, and high energy consumption, seriously restricting the large-scale and high-quality development of the phosphate-bonded refractory brick industry. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has optimized and upgraded the HLDS series of CNC servo screw presses, specifically addressing the forming challenges of phosphate-bonded refractory bricks, creating dedicated forming equipment. With the core advantages of precise pressure control, stable pressure transmission, energy efficiency, and intelligent adaptability, it has set a benchmark for high-quality phosphate-bonded refractory bricks.

Compared to ordinary refractory bricks, phosphate-bonded refractory bricks are formed by the bonding effect of phosphate binders, and their mixtures are mainly composed of high-hardness aggregates with poor fluidity, significantly increasing the forming difficulty. The mixtures of phosphate-bonded refractory bricks are made of high-alumina bauxite, corundum, mullite, etc., as aggregates, combined with phosphoric acid, phosphate, etc., as binders. The raw material particles are hard, have complex gradation, and poor fluidity. Moreover, phosphate binders are prone to water absorption and aggregation, making it difficult to exhaust during the forming process. During forming, precise control of the pressure application force, speed, and rhythm is required to achieve densification of the green body while avoiding cracking and edge and corner damage. At the same time, it is necessary to ensure uniform dispersion of the phosphate binder to meet the process requirements of different specifications of products. In addition, phosphate-bonded refractory bricks have diverse specifications, ranging from ordinary lining bricks, refractory blocks, to special-shaped furnace lining bricks and high-temperature wear-resistant bricks. The forming pressure, pressure application speed, and holding time for different types of products vary significantly, requiring extremely high process adaptability from the equipment. Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic and industry upgrading demands of phosphate-bonded refractory bricks. With the core technology of direct drive by permanent magnet synchronous servo motor + static pressure flexible pressure transmission + intelligent numerical control system, it has carried out exclusive optimization for the HLDS series of servo screw presses. The equipment's precision, stability, adaptability and energy efficiency have been comprehensively upgraded. The advantages precisely match the five key forming requirements of phosphate-bonded refractory bricks: uniformity, density, crack resistance, even dispersion of the binder and energy efficiency. It has become the preferred equipment for mass production of high-quality phosphate-bonded refractory bricks, helping refractory material enterprises to create high-quality products suitable for high-temperature working conditions and with stable performance, and seizing the market opportunities in the high-end refractory material market.

Equipped with a direct drive system of permanent magnet synchronous servo motor, it has completely eliminated the inefficient transmission structures such as traditional friction discs and clutches. The transmission chain is extremely short, with zero energy loss in energy transmission. The pressure output is fully stable and controllable throughout the process. The equipment is equipped with a dedicated numerical control pressure control module for phosphate-bonded refractory bricks independently developed by Haloong, which can digitally and precisely set the striking energy, pressurization speed, number of stepwise pressurizations and pressure holding time. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each forming process is highly consistent, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the characteristics of phosphate-bonded refractory bricks such as poor fluidity of raw materials, difficulty in exhaust of mixed materials and easy aggregation of binders, a customized stepwise pressurization process of "light pressure exhaust - slow pressure densification - long-term pressure holding" is adopted. First, light pressure is applied to loosen the raw materials and slowly exhaust the residual air inside. Then, stepwise stable pressure is applied to compact the material layer by layer (the pressure gradually increases to avoid impact). Finally, long-term pressure holding is used for shaping. This can not only ensure that all parts of the green body, including the center, edges and corners, are uniformly stressed, with density fluctuations controlled within a very small range, but also ensure that the green body structure is dense, with the apparent porosity controlled within a reasonable range. At the same time, it promotes the even dispersion of the phosphate binder, fully exerting its bonding and strengthening effects, ensuring that the finished products meet the strength standards at both room temperature and high temperatures, and increasing the qualified rate of finished products to over 99%.

It adopts a fully enclosed static pressure screw, nut and special heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform pressure transmission. It completely avoids the problems of severe impact force and stress concentration caused by traditional rigid pressurization. The pressurization process is smooth and gentle, with uniform and gentle pressure transmission. It can not only fully exhaust the internal pores of the green body and ensure its density, completely eliminating defects such as porosity, delamination and micro-cracks, but also avoid the cracking and corner damage of the green body caused by rigid impact, significantly reducing the waste of high-cost raw materials. At the same time, it effectively extends the service life of the mold, reduces material costs and improves the production efficiency of the enterprise, solving the core pain point of traditional equipment, which is "high cracking rate and high scrap rate". It also conforms to the green and energy-saving production concept of phosphate-bonded refractory bricks. Moreover, the flexible pressure transmission can avoid damaging the bonding effect of the phosphate binder, ensuring the stability of the green body during later curing, and further improving the quality of the finished product.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a step-by-step forging forming mode. According to the material, size, structural complexity (irregular structural parts, lining bricks, high-temperature wear-resistant bricks), density requirements and raw material ratio (different particle size gradation, binder addition ratio) of phosphate-bonded refractory bricks, it can flexibly adjust the slider stroke, pressurization depth and pressure application intensity, precisely matching the forming requirements of various phosphate-bonded refractory bricks, covering the full range of production scenarios of phosphate-bonded refractory bricks. There is no need to worry about the problems of uneven pressurization or green body cracking caused by deviations in raw material filling volume, particle size gradation differences and changes in the fluidity of the mixed materials. Combined with a rapid mold changing system, the mold changing is convenient and efficient, perfectly adapting to the flexible mode of multi-variety and batch production, meeting the batch supply demands of high-end fields such as metallurgy, chemical industry and power, and accommodating the forming requirements of both ordinary lining bricks and high-strength phosphate-bonded refractory bricks. It can achieve uniform density control of deep cavity and irregular phosphate-bonded refractory parts. The equipment is equipped with a dedicated forming parameter database for phosphate-bonded refractory bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, different particle size gradations, different phosphate binder addition ratios, and different density requirements of phosphate-bonded refractory bricks. It covers the forming parameters of common products such as standard phosphate-bonded lining bricks, special-shaped phosphate-bonded bricks, and high-strength high-temperature phosphate-bonded refractory bricks. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, and significantly reducing the interference of human factors on product quality. All forming parameters can be permanently saved and reused in batches, ensuring that the density, compactness, and dimensional accuracy of each batch and each product are highly consistent, with no cracking or damage to the green body, and uniform dispersion of the binder. This easily meets the strict quality requirements of the domestic and international medium and high-end markets, helping enterprises smoothly open up overseas phosphate-bonded refractory brick markets.

Compared with traditional friction presses, the Haloong servo screw press adopts an on-demand start-stop and sleep energy-saving intelligent mode. The servo motor only operates during the pressing process, and the standby state is completely zero energy consumption, with a comprehensive energy-saving rate of over 55%, and up to 60% in some working conditions. This is highly consistent with the energy-saving and environmental protection concept of phosphate-bonded refractory bricks, significantly reducing the electricity cost of phosphate-bonded refractory brick production and helping enterprises achieve green and low-carbon production. At the same time, the static pressure transmission structure has minimal wear, and is equipped with a fully automatic forced lubrication system and an oil shortage alarm device, achieving maintenance-free operation. The equipment has a low failure rate and a service life far exceeding that of traditional equipment, reducing the later operation and maintenance costs by more than 40%. It comprehensively compresses production, operation and maintenance, and consumable costs, helping enterprises achieve a green, low-carbon, and efficient profit-making production model, solving the pain points of traditional forming equipment such as "high energy consumption and complex operation and maintenance". Just like the energy-saving and efficiency-increasing results achieved by Jiaozuo Xin Cheng Group after the transformation, it helps enterprises reduce the comprehensive production cost.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, green body non-destructive testing equipment, and constant temperature conveying lines, building a fully automatic and intelligent forming production line for phosphate-bonded refractory bricks. It realizes unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention. This not only avoids damage to the green body caused by manual operation and reduces the risk of green body cracking, but also ensures forming accuracy and production efficiency, while ensuring the uniform dispersion of the phosphate binder. It also supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to remotely and real-time control the production progress and product quality. It fully conforms to the global refractory industry's trend of intelligent, digital, and green transformation, helping enterprises build high-end phosphate-bonded refractory brick intelligent production bases and enhance large-scale mass production capabilities.

Zhengzhou Haloong Machinery Co., Ltd. is a leading enterprise in the domestic electric servo screw press field. For 45 years, it has always focused on the technological innovation of refractory forming equipment and delved into the forming process pain points of high-end refractory products such as phosphate-bonded refractory bricks. It adheres to customizing technology to empower industrial upgrading. The Haloong HLDS series CNC servo screw press covers the full tonnage range from 200T to 1600T. It can provide one-to-one customized forming solutions based on the customer's requirements for phosphate-bonded refractory brick materials, specifications, production capacity, density, and raw material ratios (particle size gradation, binder addition ratio), fully meeting the mass production needs of various phosphate-bonded refractory bricks, and adapting to the supply of refractory materials in different high-temperature, high-wear, and high-corrosion fields. It solves the problems of low efficiency, uneven density, and uneven binder dispersion in traditional vibration forming, and can achieve precise forming of micro-porous structure phosphate-bonded refractory bricks, with the porosity deviation controlled within ±5%.